Cotton Waiex 191 - N191YX

[Direct C51]

Since D Sub plug clearance was mentioned, I'll give another data point for those who are interested, a Garmin 327 and Garmin GTR-200 radio fit stacked in a per plans panel. I know plug clearance with the tank is a concern for many, I was holding my breath too until I got it all installed. No issues, clearance is adequate.

[Bryan Cotton]

Here is our tray support scheme in action:








Unfortunately when we set this up on the bench, we screwed up the hangers for the transponder. We will need to redo them.

[Bryan Cotton]

I fixed the transponder tray hangars. First I hacked the bad ones:


Then I got some scrap angles to cleco to the top mount, and I gnu-vised the scraps to the bad trimmed angles. This got me a good length.


I riveted the scraps and old angles together. Then I used some scrap to duplicate the holes.


With the new angles the transponder slid in nicely. While I was working Adam had his first C152 lesson. Unfortunately the flight school here does not allow the J3 or C140 to fly when the winds exceed 11 kts. Insanity.

[kevinh]

Bryan,

Can I ask what covering you used on your glareshield? It looks very nice. ;-)

Kevin

[Bryan Cotton]

Thanks Kevin! It is flat black rustoleum.

[Bryan Cotton]

After 5 months, we are back to the Waiex. Working windscreen bow.

The car came out great!

[vwglenn]

Bout time...

Think I owe someone ten bucks.

[Bryan Cotton]

Sorry Glenn, I failed you.

We started fitting our windshield. Thanks Jeff and Sonex604.com. Here Adam is whacking down the flange:


After the initial whacks I realized it would be prudent to remove the radio and transponder. Next, a trial fit:

It seems like we don't need to trim at the back edge, but will need to take some off at the front edge so it lays down on the cowl Southco strip. We are trying to keep it tall at the back to eliminate the coke bottle look.

For the past year I had this bolt turned around the other way. I've impaled myself one too many times, so I finally flipped the bolt around.


Good to be working on the airplane again.

[Bryan Cotton]

We trimmed and did the initial drilling on the windshield. So far, so good.


Clecoed in. We used a ratchet strap to get it snug.


We still need to get the sides bent down more. Matthew and I also did a trial fit of the impeller for the hovercraft.

[Rynoth]

Looking good! For what it's worth, I ended up doubling the number of screws on the forward edge of the windshield along the upper firewall, I know other folks have done it too. I didn't have a large amount of bow between screws but it was apparent that there were bulges and more screws were easy enough to add. You may not need it with your ratchet strap method.